Apparatus for dyeing and/or washing fabric

ABSTRACT

A machine is disclosed for continuously washing and/or dyeing a moist web of fabric while the web of fabric passes therethrough. The machine comprises a processing chamber in which a plurality of drums define a path of travel therethrough for the web of fabric. Steam is introduced into the chamber to provide a humid atmosphere therein to heat the fabric. At least some of the drums are heated to a temperature above the ambient temperature to apply heat directly to the fabric raising it above the temperature obtainable by use of a steam chamber alone. Additional heat is introduced into the chamber by heated panels mounted adjacent to the path of travel of the fabric between adjacent drums which serves to maintain the temperature of the fabric as it passes from one heated drum to the next. The path of travel of the fabric passes through at least one trough which may contain water or other cleaning fluids therein to wash the fabric at elevated temperatures. The cleaning fluid (water) is also sprayed onto the fabric as it moves along its path to aid in the washing operation. Particular constructional features of the machine are disclosed which aid in washing and/or dyeing the fabric passing therethrough.

[ APPARATUS FOR DYEING AND/OR WASHING FABRIC [76] Inventor: Robert Kenneth Rogers, 4109 Glen Laurel Dr., Raleigh, NC. 27609 22 Filed: 'Oct.13,1971

21 Appl.No.: 188,870

[52] US. Cl. 68/5 E, 68/62, 68/175 [51] Int. Cl. D06t 37/02 [58] Field of Search 68/5 E, 5 D, DIG. 5, 68/9, 62, 175

[56] References Cited UNITED STATES PATENTS 2,443,990 6/l9 48 OKeefie 68/5 E 2,532,471 12 1950 Wedler 68/5 D 2,590,407 3/1952 Haas 68/175 x 2,628,883 2 1953 Dalton et al. 68/5 D x 2,899,264 8/1959 Grifiiths et al..... 68/5 D x 3,024,636 3 1962 Higginbottom 68/5 D 3,445,947 5/1969 Fleissner 68/DIG. 5 ux 3,465,551 9 1969 Schiffer et a1. 68/62 x 3,524,233 8/1970 Vorderbrugge.... 68/5 D x 3,593,543 7/1971 Bergman 68/5 D 3,595,035 7/1971 Stringer 68/5 1) Primary ExaminerHarvey C. Homsby Assistant ExaminerArthur 0. Henderson Attorney-Lawrence I. Lerner et al.

[ Dec. 4, 1973 5 7 ABSTRACT A machine is disclosed for continuously washing and- /or dyeing a moist web of fabric while the web of fabric passes therethrough. The machine comprises a processing chamber in which a plurality of drums define a path of travel therethrough for the web of fabric, Steam is introduced into the chamber to provide a humid atmosphere therein to heat the fabric. At least some of the drums are heated to a temperature above the ambient temperature to apply heat directly to the fabric raising it above the temperature obtainable by use of a steam chamber alone. Additional heat is introduced into the chamber by heated panels mounted adjacent to the path of travel of the fabric between adjacent drums which serves to maintain the temperature of the fabric as it passes from one heated drum to the next. The path of travel of the fabric passes through at least one trough which may contain water or other cleaning fluids therein to wash the fabric at elevated temperatures. The cleaning fluid (water) is also sprayed onto the fabric as it moves along its path to aid in the washing operation. Particular constructional features of the machine are disclosed which aid in washing and/or dyeing the fabric passing therethrough.

14 Claims, 1 Drawing Figure PATENTEU 41375 Y m mm 2 t 2 mmQ om APPARATUS FOR DYEING AND/OR WASHING FABRIC FIELD OF THE INVENTION BACKGROUND OF THE INVENTION Fabric has been dyed and the dyed fabric washedfor thousands of years. New fabrics have of course been continuously introduced during the years, including synthetic fabrics. As each new fabric is developed, the dyeing and washing characteristics thereof must be taken into account to determine which of the prior art processes are most suitable thereto or if, in,fact, new procedures must be developed. Notwithstandingthe long history of the fabric dyeing and washing industry, optimum techniques have not yet been developed.

Perhaps the most common method employed for dyeing fabrics are the batch processes in which a quantity of fabric is emersed in an aqueous solutionof a dye. The dye normally is heated to a temperature in the range of about 260F. The fabric is left therein for a period of time typically an hour or more. There are two interrelated reasons why such a long time interval at such a'relatively low temperature is requried. First the dye because it is in an aqueous solution is not sufficiently concentrated to dye the fabric at a high rate of speed. Secondly the fabric can withstandhigh temperatures for only short intervals of time. Therefore, since a long interval of time is required due to the low con centration of dye, the temperatures obtainable must be lowered to protect the fabric again. extending the time interval to complete the dyeing process.

The useof the lower temperature complicates the dyeing process further by introducing Barree patterns in the material. The Barree patterns are determined by and due to the previous history of the fibers in the fabric during manufacture thereof and tension developed in the fibers during knitting of thefabric. It has been found that dyeing at higher temperatures can minimize the sensitivity of the material to temperature variation with respect to the Barree problem but the period. of dyeing in an aqueous solution will not allow this.

A further drawback of the above process is that the fabric being dyed occupies the processing equipment for an extended period of time. Thus, if a sufficiently fast continuous dyeing process were developed, the active floor space of the dyeing facility could be more economically utilized. a

T o overcome these problems, a continuous dry dyeing process was developed. This process involves the application of a paste-like concentrated dye to the fabric and then passing of the fabric through a heated area (at approximately 425F.) for a short interval of time. The heat is normally supplied by open gas flames. This process tends to minimize the Barree problem but results in a low quality relatively stifi fabric due with poor hand due to the dry heat. The fact that gas flames are necessary to produce the desired heat precludes the possibility of maintaining a sufficiently humid environment. 7

Various attempts have been made to overcome this problem by passing a fabric having a concentrated dye coating thereon through a steam chamber to provide a rapid continuous moist dyeing process which produces a high quality fabric. In a continuous process, the fabric must pass into and out of a dyeing chamber which can, therefore, not be sealed. It has been found that the temperature of a dyeing chamber cannot be raised above approximately 22 0F. by the introduction of steam therein without pressurization. As a result, it appears that the prior attempts at continuous moist dyeing in steam chambers, have been abandoned.

BRIEF DESCRIPTION OF THE INVENTION The present invention overcomes the above and other problems by providing a machine for continuously moist dyeing a web of fabric and/or washing a web of fabric. The machine includes a housing having a processing chamber formed therein through which the web of fabric is passed. A plurality of drums are mounted in the chamber to define the path of travel for the web of fabric. Steam is introduced into the chamber to heat the chamber to. an ambient temperature and provide a humid atmosphere therein for maintaining the quality of the fabric. At least some of the drums defining the path are heated to a temperature greater than the ambient temperature to supply additional heat to the fabric. Still further, heated panel members or panels are disposed adjacent the path of the fabric at at least some of those portions between heated drums to maintain the temperature of the fabric.

A cleaning trough, alsoincluded in the machine, is used for holdinga reservoir of fluid through which the fabric passes on its path of travel. Cleaning fluid may.

also be sprayed onto the fabric adjacent to the trough.

A second trough is included in the machine and spans the exit opening from the chamber to provide a fluid seal for preventing steam from leaking out of the chamber and also for aiding in washing of the fabric.

The machine of this invention can be used to dye fab-' ric by having a concentrated dye applied to the. fabric before its entry into the machine. Of course, a dyeing section could be added to the machine or in some applications dye could be sprayed on the fabric as it enters the processing chamber. The elevated temperatures provided by the heated drums allow dyeing at high temperatures in short periods of time while the humid atmosphere of the steam preserves the hand of the fabric. The troughs and sprays clean excess dye stuffs from the fabric at elevated. temperatures before the fabric exits from the chamber.

It has been found that the washing of the fabric after dyeing at the elevated temperatures is sufficiently advantageous over previous washing machines that according to this invention the machine may be used for washing fabric which is not necessarily dyed therein.

DESCRIPTION OF THE DRAWINGS The sole FIGURE is a sectional side view of a machine for processing a web of fabric constructed in accordance with the teachings of this invention.

DETAILED DESCRIPTION OF THE INVENTION Referring now to the sole FIGURE of this invention The drums 13 through 19 are heated drums which may have steam or heated oil therein. The drum 13 may be heated to, for example, a temperature of between 220 to 250F. The drum 14 may be heated to, for example, a temperature between 250 and 300F. The drum 15 may be heated to, for example, a temperature between 300 and 350F. while the drums 16 and 17 may be heated to the temperature of between 350 and 500F. The drums 18 and 19 may be maintained at a temperature of about 200F. or more. The temperature will vary in the drums as the need dictates.

The drum 20 is perforated and has spray nozzles 26 and 27 therein to spray a cleaning fluid such as water on the web of fabric 12 as it passes therearound. Spray pipes 28, 29 and 31 may spray cleaning fluid on the outside of the fabric as it passes around the drums 19, 20 and 21 respectively. The drums 20 and 21 are perforated in a plurality of perforated steam pipes 32 through 34 of the fabric as it passes around the drums 19, 20 and 21 respectively. The drums 20 and 21 are perforated. A plurality of perforated steam through 32 through 34 introduce steam into the chamber 11 in the area of the drums 13 through 17.

A plurality of panels 35 through 39 heated to a temperature of, for example, about 500F., extend from the walls of the chamber 11 between the web of fabric 12 as it passes between the drums 15, 16, l7, l8 and 19 to aid in maintaining the temperature of the fabric above the ambient temperature available with steam alone as it passes between the drums temperature available with steam alone as it passes between the drums. The panels described above may be heated through any conventional heat means such as steam, electricity and the like.

The steam introduced through the perforated steam pipes 32 through 34 may be superheated to a temperature of in excess of 400F. However, the equilibrium temperature in the chamber due to theintroduction of the superheated steam is typically in the range of 220F. The heat supplied to the fabric directly from the drums enable the fabric 12 to be heated above the temperatures normally obtainable in non-pressurized steam chambers. As noted previously, the heat supplied by the panels 34 through 39 help maintain the fabric 12 at the elevated temperatures as it passes between the respective drums.

A trough 41 is located in the chamber 11 partially surrounding the drum 18. A second trough 42 partially surrounds the drum 22 and spans the exit opening 24.

In operation the web of fabric 12 is passed through a conventional dye pad 43 and 44 so that the web of fabric 12 is coated on both sides with the concentrated dye and chemicals as it enters the chamber 11 through the conventional entry port 23. If for example the fabric 12 is textured polyester, the concentrated dye applied to the web of fabric 12 can comprise a dispersed dye in a dispersing agent, a carrier to help swell the fiber, gum and acetic acid to control the PH during dye- As the coated web of fabric 12 enters the entry port 23 it passes between heated pipes 46 and 47 and under heated pipe 50 which help prevent condensation and dripping of the steam onto the fabric. The chamber 23 is also subject to suction via suction pipe to help evacuate the chamber 23 thereby preventing excess steam build up and dripping.

As the web of fabric 12 passes over the rollers 13, 14 and 15 the temperature thereof builds up through a combination of the exposure to the steam environment and the heat directly applied from the drums. It will be noted in this embodiment that the temperature of the drums progress from the temperature of the steam environment to the ultimate dye fixing temperature arrived at at the drum 16. This is done since alternate sides of the fabric pass over alternate drums which could result in facing of the material if dye fixation occurred rapidly on one side.

After the fabric 12 passes over the last dye fixing drum 17 it is immersed in a washing fluid in the trough 41. A chemical feed member 48 is provided to introduce cleansing or PH fixing fluids into the trough. It will be noted that drum 18 is at a lower temperature than the dye fixing drums but yet is still at an elevated temperature so that the still hot fabric 12 can be more easily washed. The fabric 12 moves from the drum 18 to the drum 19 while it is sprayed from the pipe 28 on the right hand side. It should be noted that a baffle 49 is interspersed between the fabric coming to and leaving the drum 19. This is done so that dirty water dripping off the fabric after it leaves the trough 41 will fall back towards the trough 41 rather than onto the fabric further down the line.

After leaving the drum 19 the fabric 12 moves onto the drum 20 where it is sprayed on both sides by the perforated pipe 29 and the spray heads 26 and 27. The fabric 12.then is passed over perforated drum 21 for further spraying from the pipe 31. It should again be noted that a baffle 41 is provided to insure that whatever water drips therefrom is fed back rather than forward onto the cleaner fabric. The fabric 12 then passes around the drum 20 through trough 22 which is filled above the exit opening 24 sov that the cloth in its final washing operation inside the chamber 1 1 passes out of the chamber 11 through a liquid barrier which helps maintain the steam in the chamber 11.

After leaving the chamber 11 the web of fabric 12 is passed over a vacuum slot 52 to draw off moisture. The fabric 12 is then passed through normal processing and dye fixing baths before being wound on a bolt or folded.

It has been found that the dyeing of fabric in this manner allows high quality dyeing to be achieved in as little as a two-minute interval. It has also been found that the washing of the fabric in the steam chamber at the elevated temperatures produces more efficient washing than was heretofore available. To this end the machine 10 may be employed even without the heated drums to wash webs of fabric. The fact that the web of fabric is held in open width on the roller cans during the raising and lowering of the temperature under humid and moist conditions prevents wrinkling thereof due to thermal shock.

It should, of course, be understood that the drums 13 through 22 are driven to move the fabric through the chamber 12. Conventional differential drums could be used to account for stretching of the web of fabric 12 as it passes through the machine.

Access doors 53 and 54 are provided one on each side of chamber 11 (only one of each such door being shown). Access door 53 comprises'a window 56 and access door 54 comprises window 57 for inspection purposes. It will be appreciated that these doors can be opened or removed enabling one to work within chamber 11.

The baffles may be pivotally and/or removeably mounted as desired to aid in the maintenance of the machine and in the treating of a web of fabric therein. In this regard, the drums may also be removably mounted.

It should be understood that while this invention has been described with respect to the specific embodiment thereof, numerous others will become obvious to those of ordinary skill in the art in light thereof.

What is claimed is:

1. A machine for processing a web of fabric; said machine including:

a housing; said housing having a chamber formed therein; said housing also having an entry opening and an exit opening formed therein for said web of fabric to pass therethrough into and out of said chamber;

a plurality of drums mounted in said chamber to define a path of travel for said web of fabric through said chamber, from said entry opening to said exit opening, said path including U-shaped portions;

means for introducing steam into said chamber to heat said chamber to an ambient temperature and provide a humid atmosphere therein;

heating means for heating at least some of said drums to a temperature greater than said ambient temperature to heat said fabric; and

heat supplying means mounted adjacent to said path of travel for supplying heat to said fabric, said heat supplying means extending into the open portions of said U-shaped portions.

2. The machine as defined in claim 1 also including:

means for applying a concentrated dye to said fabric before entering said chamber.

3. The machine as defined in claim 1 in which said heating supplying means also includes heated walls disposed on the outsides of said U-shaped portion of said path so that heat is supplied to said fabric by said particular drums defining said U-shaped portion of said path and said heated walls.

4. A machine for processing a web of fabric; said machine including:

a housing; said housing having a chamber formed therein; said housing also having an entry opening and an exit opening formed therein for said web of fabric to pass therethrough into and out of said chamber;

a plurality of drums mounted in said chamber to define a path of travel for said web of fabric through said chamber from said entry opening to said exit opening;

means for introducing into said chamber to heat said chamber to an ambient temperature and provide a humid atmosphere therein;

first heating means for heating at least some of said drums to a temperature greater than said ambient temperature to heat said fabric;

a first trough, positioned intermediate said entry opening and said exit opening, for holding a first reservoir of fluid therein mounted along said path so that said path of travel intercepts said fluid in said first reservoir; and

second heating means for heating both sides of said fabric prior to said fabric reaching said first trough.

5. The machine as defined in claim 4 including, in addition, a second trough mounted adjacent to said exit opening for holding a reservoir of fluid; said reservoir of fluid covering said exit opening to keep said steam in said chamber but allowing said web of fabric to pass therethrough.

6. The machine as defined in claim 4 in which said web of fabric is maintained with slight tension as it passes through said first reservoir.

7. The machine as defined in claim 4 also including:

means for spraying onto said web of fabric after it passes through said first reservoir.

8. The machine as defined in claim 7 also including:

means for applying a concentrated dye to said fabric before entering said chamber.

9. The machine as defined in claim 8 also including:

means mounted adjacent to said path of travel for supplying heat to said fabric.

10. The machine as defined in claim 7 also including means for spraying fluid onto said web of fabric as it travels along a portion of said path defined by a preselect ones of said plurality of drums.

11. The machine as defined in claim 10 in which said ones of said plurality of drums defining said portion of said path are perforated.

12. The machine as defined in claim 11 in which one of said perforated drums has means mounted therein for spraying fluid through said drum onto said fabric as said fabric passes thereover.

13. The machine as defined in claim 12 in which said drums define said path for said fabric so that portions of said path are generally U-shaped; and said second heating means include a heated wall extending into said U-shaped portion of said path.

14. The machine as defined in claim 13 in which said second heating means also includes additional heated walls disposed on the outsides of said U-shaped portion of said path so that heat is supplied to said fabric by said particular drum defining said U-shaped portion of said path and said heated walls. 

1. iA machine for processing a web of fabric; said machine including: a housing; said housing having a chamber formed therein; said housing also having an entry opening and an exit opening formed therein for said web of fabric to pass therethrough into and out of said chamber; a plurality of drums mounted in said chamber to define a path of travel for said web of fabric through said chamber, from said entry opening to said exit opening, said path including Ushaped portions; means for introducing steam into said chamber to heat said chamber to an ambient temperature and provide a humid atmosphere therein; heating means for heating at least some of said drums to a temperature greater than said ambient temperature to heat said fabric; and heat supplying means mounted adjacent to said path of travel for supplying heat to said fabric, said heat supplying means extending into the open portions of said U-shaped portions.
 2. The machine as defined in claim 1 also including: means for applying a concentrated dye to said fabric before entering said chamber.
 3. The machine as defined in claim 1 in which said heating supplying means also includes heated walls disposed on the outsides of said U-shaped portion of said path so that heat is supplied to said fabric by said particular drums defining said U-shaped portion of said path and said heated walls.
 4. A machine for processing a web of fabric; said machine including: a housing; said housing having a chamber formed therein; said housing also having an entry opening and an exit opening formed therein for said web of fabric to pass therethrough into and out of said chamber; a plurality of drums mounted in said chamber to define a path of travel for said web of fabric through said chamber from said entry opening to said exit opening; means for introducing into said chamber to heat said chamber to an ambient temperature and provide a humid atmosphere therein; first heating means for heating at least some of said drums to a temperature greater than said ambient temperature to heat said fabric; a first trough, positioned intermediate said entry opening and said exit opening, for holding a first reservoir of fluid therein mounted along said path so that said path of travel intercepts said fluid in said first reservoir; and second heating means for heating both sides of said fabric prior to said fabric reaching said first trough.
 5. The machine as defined in claim 4 including, in addition, a second trough mounted adjacent to said exit opening for holding a reservoir of fluid; said reservoir of fluid covering said exit opening to keep said steam in said chamber but allowing said web of fabric to pass therethrough.
 6. The machine as defined in claim 4 in which said web of fabric is maintained with slight tension as it passes through said first reservoir.
 7. The machine as defined in claim 4 also including: means for spraying onto said web of fabric after it passes through said first reservoir.
 8. The machine as defined in claim 7 also including: means for applying a concentrated dye to said fabric before entering said chamber.
 9. The machine as defined in claim 8 also including: means mounted adjacent to said path of travel for supplying heat to said fabric.
 10. The machine as defined in claim 7 also including means for spraying fluid onto said web of fabric as it travels along a portion of said path defined by a preselect ones of said plurality of drums.
 11. The machine as defined in claim 10 in which said ones of said plurality of drums defining said portion of said path are perforated.
 12. The machine as defined in claim 11 in which one of said perforated drums has means mounted therein for spraying fluid through said drum onto said fabric as said fabric passes thereover.
 13. The machine as defined in claim 12 in which said drums define said path for said fabric so that portions of said path are generally U-shaped; and said sEcond heating means include a heated wall extending into said U-shaped portion of said path.
 14. The machine as defined in claim 13 in which said second heating means also includes additional heated walls disposed on the outsides of said U-shaped portion of said path so that heat is supplied to said fabric by said particular drum defining said U-shaped portion of said path and said heated walls. 